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Oh, and now the bad news. I just observed that the lineset
is leaking, right at the vapor-line flare nut.

Argh.

My guy is back here tomorrow anyway, and I guess he's
going to have a bit more work to do than finalize a couple
of ducts... what is recommended best-practice for a
really tight/reliable flare connection? Nylog-blue?
A particular type of flaring tool? With the lineset
length already cut and very little slack to work with,
is this fixable?

I don't know if it's better to follow up on a really old thread
or start a new one; I'll try it this way first.

I finally had another service company come out and eyeball my
Daikin setup and hear the long sad litany of procedural issues.
In the meantime it had been working over hot parts of the
summer so it wasn't like it was actually broken ... but we
both agreed that a recharge would be a prudent course of action.

So that's what we did. Recovered the old stuff, and saw our share
of moisture mist drifting out of the vacuum pump on the first
pulldown. The system finally got the real pressure test it
deserved, 450 psi and not budging; the guy even put some blue
leak goop on his own manifold and fittings to make sure they
were good too. After the triple evac with nitrogen purge in
between he weighed in the 7.1 pounds that the combination of
condenser, indoor coil and lineset really wanted -- a calculation
the first guy had never even bothered with. It's right there
in the manual. This time, everything was by the book.

Then he hooked up the Service Checker to the D3-net and we
watched all the running parameters and targets and were
satisfied that everything was spot-on, so I think I'm finally
all set with this thing. The visit did cost a bit of coin,
but the peace of mind heading into heating season is worth it.
Nothing to be done about the dirty brazes, of course, but the
compressor hasn't started sounding like it has sand inside yet...

Trust me, the second company will be who gets called next [unless
I have an actual warranty issue] but really, with periodic simple
care/cleaning that I can do myself I'm hoping to not have to call
anybody for quite a while now! The new company was in fact
recommended by Daikin's very own service department, who I've
talked to a few times now. The guy was great, he was fresh out
of any number of Daikin classes and really up on the latest stuff.
We had a great tech-to-tech style chat about all the maintenance
steps, how the system works, special settings on the units, etc.
The geek-fest alone was well worth the time.

And I'll be eternally grateful to y'all here on HVAC-talk for
the industry support I needed for doing the Right Thing.